Failure analysis method for lead-acid storage battery

Abstract

The invention discloses a lead-acid storage battery failure analysis method which comprises the following steps: step 1, appearance inspection: firstly, performing appearance inspection on a return storage battery with an exhaust cock or a pressure reducing valve, judging failures caused by liquid leakage, pole reversal and collision damage defects, and making records; step 2, detecting a storage battery instrument, detecting the battery which cannot be visually judged to be invalid by adopting a Mett table, and transferring the battery which is detected by the Mett table and displays BR to a to-be-dissected area to wait for dissection analysis; step 3, battery cell voltage detection: for batteries with GB, GR and CR detected and displayed by a Mett meter, removing vent bolts or pressure reducing valves of the batteries, using a voltage test tool to measure the cell voltages one by one, transferring the batteries meeting the cell voltage requirements to a charging area for charging, and transferring the batteries not meeting the cell voltage requirements to a to-be-dissected area; and 4, charging the battery in the charging area, and then detecting the battery by using the Mett table again so as to determine whether the battery is a good battery or a defective battery.

Description

Technical Field

[0001] The invention belongs to the technical field of lead-acid battery detection, and in particular relates to a lead-acid battery failure analysis method. Background Art

[0002] All lead-acid battery manufacturers have the situation of returning batteries for analysis during the warranty period. In order to better complete this work, manufacturers will formulate after-sales return battery inspection and testing workflow and dissection and analysis workflow, and achieve the purpose of reducing battery returns through dissection and analysis, finding causes, and formulating improvement measures.

[0003] The failure modes of lead-acid batteries include reverse polarity, leakage (gas leakage), short circuit, open circuit, single cell backward, electrolyte drying, and power loss. The current inspection and testing process for after-sales batteries requires first determining whether the battery has obvious leakage, bumps, reverse polarity, and other problems, and then using a meter (select pre-charging mode) for testing. Batteries whose meter test results show GB (battery in good condition), GR (good and need to be charged), and CR (tested after charging) are supplemented as required; batteries whose meter test results show RB (replace battery) and BR (battery bad cell) are transferred to the dissection and analysis work. Then the batteries whose meter shows GB, GR, and CR need to be charged before analysis. Practice shows that the batteries whose meter shows GB, GR, and CR are mainly due to power loss, single cell backward, and battery micro-short circuit, which makes the battery unusable. Among the batteries returned after sales, the batteries whose meter shows GB, GR, and CR account for the majority, so we need to prepare a large number of chargers, sites, and personnel to carry out this work.

[0004] The return of lead-acid batteries during the warranty period will bring adverse effects, such as brand impact and increased waste. In order to reduce after-sales returns, after-sales return analysis is the key. It is necessary to find the cause of failure through after-sales return analysis and take effective measures to reduce returns based on the cause of failure. How to improve the efficiency of after-sales return analysis, improve the accuracy of analysis, and reduce analysis costs are the problems we need to solve.

[0005] Therefore, how to provide a lead-acid battery failure analysis method is a problem that technical personnel in this field need to solve urgently. Summary of the invention

[0006] In view of this, the present invention provides a lead-acid battery failure analysis method, which can improve the efficiency and accuracy of after-sales return battery determination and solve the waste problem caused by a large amount of charging work for after-sales return batteries.

[0007] In order to achieve the above object, the present invention adopts the following technical scheme: a lead-acid battery failure analysis method, which comprises the following steps:

[0008] Step 1: Appearance inspection: First, inspect the returned battery with a vent plug or pressure relief valve to determine the failure caused by leakage, reverse polarity, bump damage, and keep records;

[0009] Step 2: Battery instrument detection. Based on step 1, use a meter to detect batteries that cannot be visually determined to be failed. Move the batteries that show BR on the meter to the dissection area and wait for dissection analysis.

[0010] Step 3: Battery single cell voltage detection. For batteries with GB, GR, or CR displayed on the mitometer, remove the battery exhaust plug or pressure relief valve, use a voltage test tool to reach into the detection hole to measure the single cell voltage one by one, and transfer the batteries that meet the voltage difference requirements to the charging area for charging. Transfer the batteries that do not meet the voltage difference requirements to the waiting area for dissection and wait for dissection analysis.

[0011] The voltage test tooling includes a digital voltmeter and positive and negative probes. The positive and negative probes are L-shaped probes that are convenient for inserting into the exhaust plug hole or the pressure reducing valve hole to contact the positive and negative bus bars.

[0012] Step 4: Based on step 3, charge the batteries in the charging area and test them again with a meter to determine whether they are good batteries that need to be charged or problem batteries.

[0013] The beneficial effect of the present invention is: the returned battery is first directly inspected for appearance to determine the possible cause of failure, and then the battery is tested with a Mitt meter. For the battery that shows BR on the Mitt meter, the cause needs to be analyzed, and for the battery that shows GB, GR, and CR on the Mitt meter, further analysis is required. If all batteries are directly charged without analysis and then tested with the Mitt meter, the cause of battery failure will be misjudged, because the performance of the lagging battery in a single cell is more prominent in a non-fully charged state, and the difference between the cells will be reduced after charging, so that the problem battery is judged as a qualified battery, resulting in battery misjudgment. The battery that does not meet the requirements of the cell voltage is pre-detected and removed using a voltage test tool. Then, after charging, when the Mitt meter is used again for detection, there are only two results, GB and CR. The detection of GB means that the battery is only slightly depleted and causes low voltage, resulting in after-sales return. If it is still CR, it means that the battery has been seriously depleted and cannot be restored, and the battery failure is judged to be depleted. The present invention not only reduces battery misjudgment by detecting and analyzing the cell voltage, but also greatly reduces the number of batteries to be charged, thereby improving work efficiency.

[0014] Preferably, in the step 2, the upper cover of the battery showing BR on the Miter meter is sawed off, and the single-cell voltage is measured to find out the single-cell voltage lagging in the battery, and a detailed anatomical analysis is performed to determine the cause of the failure and keep a record.

[0015] The resulting technical effect is: this step is to further dissect and analyze the detected problematic batteries to determine their failure causes and facilitate the formulation of subsequent improvement measures.

[0016] Preferably, in step three, the batteries with a single-cell voltage range of ≤0.1V measured by the voltage testing tool are transferred to the charging area for charging, and the batteries with a single-cell voltage range of >0.1V are marked with the lowest voltage cell and transferred to the dissection area to await dissection analysis.

[0017] The resulting technical effect is that this step is to further find out the voltage lagging cell and avoid the subsequent invalid charging detection process.

[0018] Preferably, both the positive electrode probe and the negative electrode probe are provided with an insulating sheath, and the insulating sheath is provided with a protruding column section for easy gripping.

[0019] The resulting technical effect is that both the positive probe and the negative probe are provided with insulating sheaths. It can be understood that except for the needle head, the rest are wrapped by the insulating sheath. Compared with the traditional probe, the L-shaped probe provided in the present invention can enter the interior of the single cell through the exhaust plug hole or the pressure reducing valve hole, that is, the detection hole, to contact the positive and negative bus bars, thereby achieving the purpose of testing the voltage of the single cell, which is impossible for conventional straight probes.

[0020] Preferably, in step three, the upper cover of the battery that does not meet the single-cell voltage is sawed off, and a detailed anatomical analysis is performed on the marked lowest voltage cell, and records are kept after the failure cause is determined.

[0021] The resulting technical effect is: this step is to analyze and determine the cause of the lagging cell.

[0022] Preferably, in the step 4, after charging the battery in the charging area, let it stand for 1 day and test it with a meter. The meter shows GB or CR. If it is GB, it is determined that the battery is a good battery. If it is CR, it is determined that the battery has been severely depleted and cannot be recovered. The battery failure is determined to be depleted, and the above batteries are analyzed and recorded.

[0023] The resulting technical effect is: if the after-sales return is caused by a slight lack of power resulting in low voltage, then the charging test will be normal; if the battery is damaged and cannot be repaired, then the charging test will be abnormal. BRIEF DESCRIPTION OF THE DRAWINGS

[0024] Figure 1 This is a schematic diagram of the battery cover;

[0025] Figure 2 A diagram showing the inside of a battery with the battery cover removed;

[0026] Figure 3 A top view of the battery with the vent plug or pressure relief valve removed;

[0027] Figure 4 This is a structural diagram of the voltage testing tool used in the present invention.

[0028] 1 digital display voltmeter, 2 insulating protective cover, 21 protruding column section, 3 positive probe, 4 negative probe, 5 detection hole, 6 positive bus, 7 negative bus. DETAILED DESCRIPTION

[0029] The following will be combined with the drawings in the embodiments of the present invention to clearly and completely describe the technical solutions in the embodiments of the present invention. Obviously, the described embodiments are only part of the embodiments of the present invention, not all of the embodiments. Based on the embodiments of the present invention, all other embodiments obtained by ordinary technicians in this field without creative work are within the scope of protection of the present invention.

[0030] See the attached Figures 1 to 4 According to a lead-acid battery failure analysis method according to an embodiment of the present invention,

[0031] A failure analysis was conducted on a batch of 12V flooded and lean (AGM) aftermarket returned lead-acid batteries with vent plugs or with pressure relief valves.

[0032] Step 1: Appearance inspection: First, inspect the returned battery with a vent plug or pressure relief valve to determine the failure caused by leakage, reverse polarity, bump damage, and keep records;

[0033] Step 2: Battery instrument detection. Based on step 1, use a battery meter to detect batteries that cannot be visually determined to be failed. The battery meter can be a battery tester of the MDX-600 series. Move the battery that shows BR on the battery meter to the dissection area for dissection analysis.

[0034] Step 3: Battery single cell voltage detection. For batteries with GB, GR, or CR displayed on the mitometer, remove the battery exhaust plug or pressure relief valve, and use the voltage test tool to measure the single cell voltage one by one. Batteries that meet the voltage difference requirements are transferred to the charging area for charging, and batteries that do not meet the voltage difference requirements are transferred to the waiting area for dissection and analysis.

[0035] The voltage test tooling includes a digital voltmeter 1, a positive probe 3 and a negative probe 4. The voltage test range is 5V~5V, and the accuracy is 0.01V. The positive probe and the negative probe are both stainless steel L-shaped probes. The L-shaped positive and negative probes are easy to extend into the exhaust plug hole or the pressure reducing valve hole to contact the positive bus 6 and the negative bus 7; refer to the attached Figure 3, the voltmeter using the existing straight probe cannot contact the positive and negative bus bars of a single cell, and thus cannot measure the voltage of each cell of the battery, and the exhaust plug hole or the pressure reducing valve hole is recorded as the detection hole 5;

[0036] Step 4: Based on step 3, charge the batteries in the charging area and test them again with a meter to determine whether they are good batteries that need to be charged or problem batteries.

[0037] In step 2, saw off the upper cover of the battery that shows BR on the Miter meter, measure the single-cell voltage, find out the single-cell voltage lagging in the battery, conduct a detailed anatomical analysis, determine the cause of failure and keep a record.

[0038] In step three, the batteries with a single-cell voltage difference of ≤0.1V measured by the voltage test tool are transferred to the charging area for charging, and the batteries with a single-cell voltage difference of >0.1V are marked with the lowest voltage cell and transferred to the dissection area to wait for dissection analysis.

[0039] Both the positive probe 3 and the negative probe 4 are provided with an insulating sheath 2, and a protruding column section 21 for easy gripping is provided on the insulating sheath 2. It should be noted that the insulating sheath should cover other areas except the probe head. Except for the part where the probe end contacts the bus, the rest of the probe is fully insulated to prevent the positive and negative poles from short-circuiting and overlapping.

[0040] In step three, saw off the top cover of the battery that does not meet the single-cell voltage, perform a detailed anatomical analysis on the marked lowest voltage cell, and make a record after determining the cause of failure.

[0041] In step 4, after charging the battery in the charging area, let it stand for 1 day and use a meter to test it. The meter will display GB or CR. If it is GB, it is determined that the battery is a good battery. If it is CR, it is determined that the battery has been severely depleted and cannot be restored. The battery failure is determined to be depleted. Make analysis records of the above batteries.

[0042] Compared with the prior art, the lead-acid battery failure analysis method of the present invention eliminates bad batteries in GB, GR, and CR batteries displayed on the Miter table, reduces unnecessary charging processes in after-sales return battery analysis, saves time, reduces power consumption, improves after-sales return analysis efficiency, improves analysis accuracy, and reduces analysis costs.

[0043] As for the device and the method of use disclosed in the embodiment, since they correspond to the method disclosed in the embodiment, the description is relatively simple, and the relevant parts can be referred to the description of the method part.

[0044] The above description of the disclosed embodiments enables those skilled in the art to implement or use the present invention. Various modifications to these embodiments will be apparent to those skilled in the art, and the general principles defined herein may be implemented in other embodiments without departing from the spirit or scope of the present invention. Therefore, the present invention will not be limited to the embodiments shown herein, but rather to the widest scope consistent with the principles and novel features disclosed herein.

Claims

1. A lead-acid battery failure analysis method, characterized in that: The following steps are involved: Step 1: Appearance inspection: First, inspect the returned battery with a vent plug or pressure relief valve to determine the failure caused by leakage, reverse polarity, bump damage, and keep records; Step 2: Battery instrument detection. Based on step 1, use a meter to detect batteries that cannot be visually determined to be failed. Move the batteries that show BR on the meter to the dissection area and wait for dissection analysis. Step 3: Battery single cell voltage test. For batteries with GB, GR, or CR displayed on the mitometer, remove the battery exhaust plug or pressure relief valve, use a voltage test tool to reach into the test hole to measure the single cell voltage one by one, and transfer the batteries that meet the single cell voltage requirements to the charging area for charging. Transfer the batteries that do not meet the single cell voltage requirements to the waiting area for dissection and wait for dissection analysis. The voltage test tooling includes a digital voltmeter and positive and negative probes. The positive and negative probes are L-shaped probes that are convenient for inserting into the exhaust plug hole or the pressure reducing valve hole to contact the positive and negative bus bars. Step 4: Based on step 3, charge the battery in the charging area and test it again with a meter to determine whether it is a good battery or a defective battery.

2. A lead-acid battery failure analysis method according to claim 1, characterized in that: In the step 2, the upper cover of the battery showing BR on the Miter meter is sawed off, and the single-cell voltage is measured to find out the single-cell voltage lagging in the battery, and a detailed anatomical analysis is performed to determine the cause of the failure and keep a record.

3. A lead-acid battery failure analysis method according to claim 1, characterized in that: In the step three, the batteries with a single-cell voltage difference of ≤0.1V measured by the voltage testing tool are transferred to the charging area for charging, and the batteries with a single-cell voltage difference of >0.1V are marked with the lowest voltage cell and transferred to the dissection area to wait for dissection analysis.

4. A lead-acid battery failure analysis method according to claim 3, characterized in that: Both the positive electrode probe and the negative electrode probe are provided with insulating sheaths, and the insulating sheaths are provided with protruding column sections for easy grasping.

5. A lead-acid battery failure analysis method according to claim 3, characterized in that: In the step three, the upper cover of the battery that does not meet the single-cell voltage is sawed off, and a detailed anatomical analysis is performed on the marked lowest voltage single cell, and records are kept after the failure cause is determined.

6. A lead-acid battery failure analysis method according to claim 1, characterized in that: In the step 4, after charging the battery in the charging area, let it stand for 1 day and use a meter to test it. The meter shows GB or CR. If it is GB, it is determined that the battery is a good battery. If it is CR, it is determined that the battery has been severely depleted and cannot be restored. The battery failure is determined to be depleted. The above batteries are analyzed and recorded.

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